Audi Workshop Service and Repair Manuals

Removing gearbox   Note All cable ties which are released or cut open when removing the gearbox must be refitted in the same position when installing the gearbox. –  Remove engine cover panel. –  Obtain radio code on vehicles with coded radio. –  With the ignition switched off, disconnect battery earth strap.

–  Detach air hose -1- and connector -2- at air mass meter -G70-. –  Remove bolts -3- and -4- and detach air cleaner housing → Repair group 24.

Up to gearbox build date 02 08 8 –  Unplug connector from reversing light switch -F4--arrow-.

From gearbox build date 03 08 8 onwards –  Unplug connector from reversing light switch -F4--arrow 3-.   Note Ignore -arrow 1- and -arrow 2-. Continued for all vehicles

–  Use screwdriver to lever off front selector rod -1- from gearbox selector lever -2-. –  Then remove securing clip -3-. –  Pull intermediate lever -4- off support bracket. –  Turn intermediate lever -4- and pull it off selector rod -5-.

–  Then lever off both coupling rods -arrows-. –  Remove gearbox selector lever -1- from gearbox. –  Now remove the two bolts -2- for support bracket -3- on gearbox. –  Take off support bracket together with coupling rods and gearbox selector lever.

–  Now remove slave cylinder -arrows-, move clear to the top and secure with wire. Do not disconnect pipes.   Note Do not depress clutch pedal.

–  Detach earth strap at upper engine/gearbox connecting bolt -1-. –  Unbolt cable retainer -3- at starter -arrow- and place to one side. –  Then remove upper securing bolt - 2- on starter. –  Remove all engine/gearbox connecting bolts which are accessible from above. –  If there are hoses and cable connections in area of engine lifting eyes for support bracket -10 - 222 A-, remove these now.

–  Assemble support bracket -10 - 222 A- together with racks -10 - 222 A/1-. –  Partly take up weight of engine/gearbox assembly with the spindles.

–  Detach retainer for power steering pipe from rear bolt for gearbox bracket -arrow 1-.   Note On some vehicles the retainer for the power steering pipe is fitted to the gearbox bracket. –  Remove hexagon bolts -arrows 2- from gearbox mounting on left side. –  Remove gearbox bracket -arrows 3- and -arrow 1-. –  Unplug connector from speedometer sender -G22--arrow 4-. –  Disconnect all other electrical connections and earth wires from gearbox and from engine/gearbox securing bolts.

–  Unscrew bolts -arrows- and remove noise insulation completely. –  Remove wheel housing liner (left-side). –  Remove starter → Rep. Gr.27.

–  If fitted, remove protective cover for right inner constant velocity joint -arrows-. –  Turn wheels onto left lock. –  Disconnect drive shafts from flange shafts and tie up as high as possible, taking care not to damage surface coating.

–  Remove small cover plate -A- for flywheel behind right-hand flange shaft -arrows-. –  Remove catalytic converter → Rep. Gr.26.

–  Remove pendulum support -arrows-. –  Remove rear engine/gearbox connecting bolt -arrow A-. –  Lower engine/gearbox assembly slightly using left-hand spindle.

–  Bolt support rail -VW 457/1- to both threaded holes for pendulum support securing bolts on subframe. –  Spacers totalling 6 mm must be inserted between subframe and support rail -VW 457/1-. A -  2 hexagon bolts M8 x 25 –  Fit engine support -3300 A- and secure -arrows-. –  Carefully press engine/gearbox unit forwards.   Note Do not damage power steering pipe when moving engine/gearbox assembly. –  Assemble gearbox jack with gearbox support -3282-, adjustment plate -3282/5- for “020” gearbox and support elements as follows: –  Place adjustment plate -3282/5- on gearbox support -3282- (adjustment plate only fits in one position). –  Align arms of gearbox support according to holes in adjustment plate.

–  Bolt on support elements -A-, as illustrated on adjustment plate.

–  Run gearbox jack under vehicle; arrow symbol -B- → Anchor, Fig. V34-2577 on adjustment plate points to front of vehicle. –  Align adjustment plate parallel to gearbox and lock safety support on gearbox. –  Remove bottom engine/gearbox connecting bolts.

–  Push the gearbox off the dowel sleeves and swing carefully towards the subframe. –  Slightly lower gearbox and tilt via spindles of gearbox support -3282-.

–  Then lower gearbox carefully, guiding right-hand flange shaft -A- past flywheel as illustrated and left-hand flange shaft -B- past subframe. –  When lowering the gearbox, change position of gearbox using the spindles on gearbox support -3282-.   Note Do not damage power steering pipe when lowering gearbox. Transporting gearbox Gearbox lifting tackle -3336- can be used to transport the gearbox and also when setting up gearbox support -3282-.

–  Bolt gearbox lifting tackle -3336- to clutch housing.

–  Set support arm on sliding bracket by means of locking pin -arrow-. Number of holes visible = 6 –  Take up gearbox with workshop hoist and gearbox lifting tackle -3336-. –  Set down gearbox as required (for example in transport container).